N8945E

Part: FUSE — BLOWN (EMERGENCY LIGHTS) · airframe 86,212 hrs · 80,554 cycles

DURING THE LINE CHECK, THE RT OVERWING EMERGENCY EXIT SIGN AND THE EMERGENCY PATHWAY LIGHTING FOR SEVERAL SEAT ROWS WERE FOUND TO BE INOPERATIVE. MAINTENANCE FOUND THE ASSOCIATED FUSE BLOWN AND REPLACED IT. OPERATIONAL CHECK WAS GOOD. (A)

Part: COMPRESSOR — STALLED (NR 2 ENGINE) · airframe 85,737 hrs · 80,117 cycles

DURING TAKEOFF ROLL AT 110 KNOTS, ENGINE NR 2 EXPERIENCED 2 COMPRESSOR STALLS. FLIGHT CREW ABORTED TAKEOFF AND RETURNED TO GATE. FLIGHT CREW REPORTED SNOW CONTAMINATED RUNWAYS. MAINTENANCE PERFORMED POST STALL INSPECTIONS AND GROUND RUN ON ENGINE NR 2.

Part: SKIN — DAMAGED (BS 185-210) · airframe 85,028 hrs · 79,846 cycles

DURING GROUND OPERATIONS, FUSELAGE SKIN WAS DAMAGED BY VEHICLE IMPACT AT BS 185 TO BS 210 S26R-S30R AND BS 194 TO BS 229 S24R-S26R. REPAIRED PER EA 99-210976.

Part: FRAME — CRACKED (BS 1004) · airframe 84,946 hrs · 79,401 cycles

DURING "H" CHECK, FOUND CRACKS AND WEAR IN FRAME ANGLE AT BS 1004 BS 0. REPAIRED PER EA 99-210176.

Part: SHEAR TIE — DAMAGED (BS 332 S23-25L) · airframe 84,245 hrs · 78,748 cycles

DURING GROUND OPERATIONS, BELT LOADER IMPACTED FUSELAGE CAUSING DAMAGE TO SHEAR TIE AT S23L-25L BS 332. REPAIRED PER EA 99-206447.

Part: LONGERON — DAMAGED (BS 285 L29-30L) · airframe 84,425 hrs · 78,748 cycles

DURING GROUND OPERATIONS, BELT LOADER IMPACTED FUSELAGE DAMAGING L29L AND L30L AT BS 285. REPAIRED PER EA 99-206445.

Part: SKIN — DAMAGED (BS 288-375) · airframe 84,245 hrs · 78,748 cycles

DURING GROUND OPERATIONS, BELT LOADER IMPACTED FUSELAGE CAUSING DAMAGE TO LOWER BELLY SKIN L26R-L26L AT BS 288-375 AND UPPER LT FUSELAGE SKIN L26L-L23L AT BS 305-361. REPAIRED PER EA 99-206446.

Part: DUCT — LOOSE (A/C PACK) · airframe 83,786 hrs · 78,313 cycles

SHORTLY AFTER TAKEOFF THE FLIGHT ATTENDANT REPORTED EXCESSIVE SMOKE IN THE CABIN AND ALSO THAT VERY HOT AIR COMING FROM DUCTS. THE CREW DECLARED A YELLOW EMERGENCY AND RETURNED TO AN UNEVENTFUL LANDING BACK AT DEPARTURE. NO MENTION OF COM PROCEDURE COMPLIANCE OR OF PACK CONFIGURATION. MAINTENANCE FOUND A LOOSE DUCT AT THE RT PACK AND SECURED IT. NO LEAKS AT THE APU WERE FOUND AND NO CONTAMINATION OF EITHER THE 8TH OR 13TH STAGES WAS FOUND. THE COALESCER BAGS WERE CLEANED AND PACK BURNOUT PROCEDURES PERFORMED. ALL CHECKS WERE GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: WATER SEPARATOR — DAMAGED (CABIN AIR) · airframe 81,315 hrs · 75,988 cycles

DURING CLIMBOUT AT ABOUT 600 FEET THE FLIGHT ATTENDANT NOTIFIED THE COCKPIT THAT THE CABIN HAD SMOKE COMING OUT OF ALL VENTS AND ITS ACCOMPANIED BY AN ACRID SMELL. THE FLIGHT RETURNED TO AN UNEVENTFULL LANDING BACK AT MSP. NO MENTION OF COM PROCEDURE COMPLIANCE. MAINTENANCE COULD NOT FIND A SOURCE FOR THE SMOKE, NO EVIDENCE OF ANY FIRE WAS FOUND. ALL ENGINE AND COMPONENT OIL LEVELS WERE NORMAL. THE WATER SEPARATOR BAGS WERE REPLACED, SYSTEM WAS PURGED AND THE AIRCRAFT HAS RETURNED TO SERVICE.

Part: SHUTOFF VALVE — LEAKING (HYD SYSTEM) · airframe 80,609 hrs · 75,311 cycles

THE RIGHT HYDRAULIC SYSTEM FAILED IN FLIGHT AND EXPERIENCED A COMPLETE LOSS OF FLUID. COMPLIED WITH COM PROCEDURES AND AIRCRAFT CONTINUED TO SCHEDULED DESTINATION. LANDING AT CMH WAS UNEVENTFUL AND MAINTENANCE REPLACED A LEAKING RUDDER HYDRAULIC POWER SHUTOFF VALVE. ALSO THE RIGHT SYSTEM FILTERS, ENGINE DRIVEN PUMP, AND ELECTRIC PUMP WERE ALL REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. AIRCRAFT RETURNED TO SERVICE.

Part: PUMP — LEAKING (RT HYD SYSTEM) · airframe 79,985 hrs · 74,729 cycles

RIGHT HYDRAULIC SYSTEM QUANTITY DROPPED TO LESS THAN 3 QUARTS DURING DESCENT. COM PROCEDURES COMPLIED WITH AND PRESSURE WAS NORMAL. FLIGHT LANDED WITHOUT INCIDENT AT IAH AND THEN HYDRAULIC QUANTITY DROPPED TO ZERO AFTER TOUCHDOWN. MAINTENANCE FOUND A LEAK AT THE PRESSURE OUTLET OF THE AUXILIARY HYDRAULIC PUMP. THE ELECTRIC AND THE ENGINE DRIVEN PUMPS ALONG WITH ALL FIVE OF THE RIGHT HYDRAULIC SYSTEMS FILTERS WERE REPLACED. THE AIRCRAFT HAS RETURNED TO SERVICE.

Part: WEB — CRACKED · airframe 74,202 hrs · 69,504 cycles

During Hck in ATL, a .25" crack was found on the doorjamb web at station 617 RHS. Repaired per EA 99-181318. Material 2024-t42 AL

Part: WEB — CRACKED · airframe 74,202 hrs · 69,504 cycles

During Hck in ATL, a .25 inch crack was found on the doorjamb web at station 617 RHS. Material .032" 2024-t42. Repaired per EA. 99-181318.

Part: WEB — CRACKED (FUSELAGE) · airframe 74,202 hrs · 69,504 cycles

DURING HCK IN ATL, A 5 INCH LONG CRACK WAS FOUND IN THE RIGHT HAND CUSP MEMBRANE AT STA 617. THE DAMAGED SECTION OF THE CUSP MEMBRANE EXTENDS FROM STA 598 TO 658. THIS EA 99-181334 PROVIDES SPLICE INSTRUCTIONS TO REPLACE ONLY THE PORTION OF MEMBRANE BETWEEN 598 AND 617.

Part: WEB — CRACKED · airframe 74,202 hrs · 69,504 cycles

During H ck in ATL a 5" long crack was found in the RH floorbeam web cusp membrane at STA 617. The damaged section of the cusp membrane extends from station 598 to sta 658. Material .202" 7075-t6 AL. Repaired per EA 99-181334.

Part: FLOORBEAM — CRACKED (FUSELAGE) · airframe 74,202 hrs · 69,504 cycles

DURING H-CK AT ATL BASE MTC, THE UPPER CAP OF THE STATION 200 FLOORBEAM T-CAP WAS FOUND WITH A CRACK AT X=44 RT. REPAIRED PER EA 99-181292.

Part: CONTROLLER — FAILED (CABIN PRESSURE)

CABIN PRESSURE AUTO FAIL LIGHT ILLUMINATED CLIMBING THROUGH 14,000 FEET. OXYGEN MASKS WERE DEPLOYED THROUGHOUT CABIN AND FLIGHT WAS RETURNED TO DFW. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED BOTH CABIN PRESSURE CONTROLLERS, OPERATIONAL CHECK NORMAL. AIRCRAFT RETURNED TO SERVICE.

Part: FRAME — DAMAGED (BS 1038)

DURING SVI, AFT ACCESSORY COMPARTMENT FS 1038 LEFT FRAME HAS FASTENER HOLE ELONGATED TO .310 AT HOLE NR 22 FOR UPPER REAR SPAR CAP. REPAIRED PER EA 99-169369.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND EMERGENCY LIGHTS INOPERATIVE IN TAIL COMPARTMENT CATWALK. MAINTENANCE REPLACED THE POWER SUPPLY.

Part: TR UNIT — MALFUNCTIONED (E/E COMPT)

WEATHER RADAR SYSTEM FAILED AFTER TAKEOFF. FLIGHT WAS RETURNED TO DTW AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED RADAR TRANSCEIVER, OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND EMERGENCY PATH LIGHTS IN TAIL CONE CATWALK AREA INOPERATIVE. REPLACED BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND CATWALK EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK NORMAL.

Part: POWER SUPPLY — DISCHARGED (TAIL CONE)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL CONE CATWALK EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY, OPERATIONAL CHECK NORMAL.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND CATWALK EMERGENCY LIGHTS INOPERATIVE. REPLACED POWER SUPPLY, OPERATIONAL CHECK NORMAL.

Part: BATTERIES — DISCHARGED (CABIN)

DURING LINE MAINTENANCE INSPECTION, FOUND OVERWING EMERGENCY EXIT LIGHTS INOPERATIVE. REPLACED BATTERIES IN BOTH PACK, OPERATIONAL CHECK NORMAL.

Part: CLIPS — OUT OF ADJUST (TAIL CONE)

DURING L-CHECK, FOUND THAT EXCESSIVE FORCE WAS REQUIRED TO PULL INTERIOR TAIL CONE RELEASE HANDLE FROM RETAINING CLIPS. ADJUSTED CLIPS, FUNCTIONAL CHECK OK.

Part: FRAME — CRACKED (BS 1143)

DURING L-CHECK, FOUND CRACK IN CANTED FRAME AT INTERIOR TAIL CONE RELEASE HANDLE FS 1143. REPAIRED PER EA 99-112293.

Part: SKIN — CRACKED (HORIZ STAB)

DURING L-CHECK, FOUND CRACK IN LEFT HORIZONTAL STABILIZER SKIN TOP INBOARD AFT AREA. REPAIRED PER EA 99-112305.

Part: WIRE — FAILED (TAILCONE)

DURING PERIODIC CHECK, FOUND TAILCONE EMERGENCY SLIDE LIGHTS INOPERATIVE. MAINTENANCE REPAIRED WIRING. OPERATIONAL CHECK NORMAL.

Part: BATTERY PACK — DISCHARGED (RT NACELLE)

DURING PERIODIC CHECK, FOUND RIGHT NACELLE EMERGENCY LIGHT INOPERATIVE. REPLACED BATTERY PACK. OPERATIONAL CHECK NORMAL.

Part: FILTER — CLOGGED (LT ENGINE)

DURING TAKEOFF ROLL, THE LEFT ENGINE OIL STRAINER LIGHT ILLUMINATED. CREW ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE REPLACED LEFT ENGINE OIL FILTER, OPERATIONAL CHECK OK.

Part: FILTER — CLOGGED (RT ENGINE)

DURING TAKEOFF ROLL, THE RIGHT ENGINE OIL STRAINER LIGHT ILLUMINATED. CREW ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE REPLACED RIGHT ENGINE OIL FILTER, OPERATIONAL CHECK OK.

Part: FUEL CONTROL — OUT OF TRIM (NR 1 ENGINE)

AS TAKEOFF POWER WAS APPLIED THE NUMBER ONE ENGINE EPR INDICATION WOULD NOT REACH TARGET EPR SETTING. CREW ABORTED TAKEOFF AND RETURNED TO GATE. MAINTENANCE TRIMMED THE NUMBER ONE ENGINE FUEL CONTROL AND DRAINED THE MOISTURE TRAP, OPERATIONAL CHECK WAS OK.

Part: ACM — MALFUNCTIONED (LEFT)

FLIGHT ATTENDANT REPORTED BURNING SMELL IN CABIN AFTER TAKEOFF. FLIGHT RETURNED TO MEM AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED AND FOUND FUMES COMING FROM LEFT AIR CYCLE MACHINE. REPLACED AIR CYCLE MACHINE, LEAK AND OPERATIONAL CHECK NORMAL.

Part: OIL FILTER — CONTAMINATED (RT ENGINE)

DURING TAKEOFF ROLL, THE RIGHT ENGINE OIL STRAINER CLOG LIGHT ILLUMINATED. CREW ABORTED TAKEOFF AND RETURNED TO THE GATE. MAINTENANCE REPLACED THE RIGHT ENGINE MAIN OIL STRAINER, LEAK AND OPERATIONAL CHECK OK.

Part: BATTERY PACK — MALFUNCTIONED (FWD ENTRY WAY)

DURING LINE MAINTENANCE INSPECTION, FOUND EMERGENCY LIGHTS DIM IN FORWARD ENTRY WAY. REPLACED BATTERY PACK, OPERATIONAL CHECK NORMAL.

Part: EVAC SLIDE — FAILED TEST (FWD SERVICE DOOR)

DURING PERIODIC CHECK, FORWARD SERVICE DOOR EVACUATION SLIDE FAILED BATTERY TEST. REPLACED SLIDE.

Part: SLIDE — LOW PRESSURE (TAIL SECTION)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL EVACUATION SLIDE LOW ON PRESSURE. REPLACED SLIDE.

Part: OIL SYST — REQD SERVICE (APU)

PREVIOUS TO DEPARTURE, ENGINE NR 2 GENERATOR PLACED ON MEL AND APU WAS USED FOR GENERATOR POWER. DURING CRUISE FLIGHT, THE APU LOW OIL LIGHT ILLUMINATED AND SHORTLY THERE AFTER, THE APU AUTO SHUTDOWN. CAPTAIN DECLARED AN EMERGENCY AND DIVERTED TO FAR. AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE PERSONNEL SERVICED APU WITH OIL, GROUND RUN AND LEAK CHECKED, NO LEAK NOTICED.

Part: BATTERY PACK — DISCHARGED (TAIL CONE)

DURING LINE MAINTENANCE INSPECTION, FOUND TAIL CONE EMERGENCY LIGHTS INOPERATIVE. REPLACED BATTERY PACK AND OPERATIONAL CHECK NORMAL.

Part: AUX HYD PUMP — MALFUNCTIONED (LANDING GEAR)

LANDING GEAR WAS VERY SLOW TO RETRACT AFTER TAKEOFF. NOSE GEAR RED UNSAFE LIGHT EXTINGUISHED AT 3,500 FEET AND BOTH MAINS AT 4,500 FEET. FLIGHT RETURNED TO MSP AND LANDED WITHOUT INCIDENT. REPLACED THE LANDING GEAR ALTERNATE HYDRAULIC PUMP DUE TO INTERNAL BYPASSING. OPERATIONAL CHECK NORMAL ON GEAR SWING AND AIRCRAFT RETURNED TO SERVICE.

Part: BATTERY PACK — DISCHARGED (TAILCONE)

DURING LINE CHECK, FOUND EMERGENCY ESCAPE PATH LIGHTING IN TAILCONE AREA INOPERATIVE. REPLACED THE BATTERY PACK AND OPERATIONAL CHECK GOOD.

Part: POWER SUPPLY — INOPERATIVE (CABIN)

DURING LINE CHECK, FOUND TAILCONE EMERGENCY LIGHTS AND ENTRY DOOR EMERGENCY EXIT SIGN INOPERATIVE. REPLACED POWER SUPPLY, BATTERIES AND REPLACED FUSE. OPERATIONAL CHECK GOOD.

Part: FITTING — CRACKED (CARGO DOOR)

DURING LINE CHECK, FOUND A CRACK IN THE UPPER AFT CARGO DOOR STOP FITTING, FORWARD CARGO DOOR JAMB. REPLACED FITTING PER SRM 51-30-2.

Part: DUCT — DISCONNECTED (RT PACK)

LOSS OF CABIN PRESSURIZATION OCCURRED AT 29,000 FEET, CABIN ALTITUDE CLIMBED TO 11,000 FEET. INITIATED EMERGENCY DESCENT PROCEDURES AND PRESSURE WAS REGAINED AT 17,000 FEET. CONTINUED TO DESTINATION AND LANDED WITHOUT INCIDENT. OXYGEN MASKS DID NOT DEPLOY. FOUND RIGHT PACK FLEX DUCT FORWARD OF COLD AIR CHECK VALVE DISCONNECTED AND CLAMP MISSING. REPLACED CLAMP AND INSTALLED NEW FLEX DUCT. OPERATIONAL CHECK OK, AIRCRAFT RETURNED TO SERVICE.

Part: SKIN — CORRODED (FS 57 69)

DURING ACCEPTANCE CHECK AND PRIOR TO SERVICE, FOUND CORROSION ON THE RIGHT SIDE NOSE LANDING GEAR WHEELWELL SKIN FS 57 - 69. REPAIRED SKIN (P/N 5911400) PER EA 99-94862.

Part: BLKHD WEB — CRACKED (FS 996)

DURING ACCEPTANCE CHECK AND PRIOR TO SERVICE, FOUND THE AFT PRESSURE BULKHEAD WEB FS 996 TO HAVE LOOSE RIVETS (LONGERON 26R - 27R), CRACKS (AT LONGERON 28R, 29R), AND CORROSION (BL 0). REPAIRED WEB (P/N 5910130-65) PER EA 99-94812.